Rebuilding a 3S.

[bbarnumboy]

Good job!

[macatak]

Sarah, which sway bar mount?

[PearlWhiteMR2]

Duncan, both of them are ok. I have to tap the holes because the bolts broke off in the subframe.

Sent from my MB860 using Tapatalk 2

[macatak]

ack!!!! 's no fun

[PearlWhiteMR2]

Have had to tap so many now, what's another few haha.

So all that's left to do (provided nothing else comes up):

-fix exhaust (hangar broke off)
-fix sway bar mounts
-fix leaking radiator (taking to a shop to have it repaired)
-fill/bleed coolant
-check oil pressure, pressure test cooling system
-find and install turbo stay/dipstick!
-fix reason starter relay isn't getting power
-install front lip/underbody panels
-tap rear driver's caliper bracket
-fix driver's side axle seal (leaking)
-install catch can
-adjust clutch
-replace cross-threaded wheel stud on driver's front wheel

[PearlWhiteMR2]

So we didn't wire the starter up correctly, so now it starts with the key. Also installed the oil pressure sender, but the gauge just flickers back and forth and when you start the car it pins to maximum.. does anyone else have Prosport gauges know anything about this or had this problem? I am hoping the gauge isn't messed up or something.

Here are a couple pics of the new water pump and the threads that the idler pulley bolt stripped out:




Next I have to pull the radiator and take it to a repair shop, hopefully it's nothing too major. After that we'll fill it with coolant and test the engine itself to ensure it's running properly.

[macatak]

the gauge just flickers back and forth and when you start the car it pins to maximum

could be bad ground, temp gauge on the MK1 was doing the same thing when the tab on the sender cracked from old age.
tab snapped off inside the connector when I went to remove it.

this is interesting
http://forums.nasioc.com/forums/showthread.php?t=1878073

[dh4ever]

my aftermarket gauge spiked at like 140psi, it was the sensor that was the problem. I had to buy a whole new gauge to get a new sensor

[PearlWhiteMR2]

Got the rad back, it had to be rebuilt with a new core as the old core was partially plugged and it literally fell apart in your hands. There was not much heat transfer ability left in it. It was $260 to rebuilt it and retain the brass end tanks, which are a desirable thing as they don't make these anymore! The shop I took it to was very good, professional, and had it done within two days.

Installed this along with the new axle seal last night. Unsure why the previous axle seal that was installed was leaking, there didn't appear to be anything wrong with it and there were no nicks or burrs on the axle or the housing. The new one appears to be ok though!

The oil pressure gauge also appears to be working now, all by itself.. I don't trust it much but it does seem to be reading correctly. It has healthy oil pressure and good vacuum according to the boost gauge as well.

Filled it up with water and pressure tested to ensure no leaks, and it seemed ok! Drained the old fuel out of the tank and added new, fresh 91 octane. Did one last once over and then put the wheels back on, lowered it down, and took it for the first drive!

It felt AMAZING! The only problems were a fender liner that was loose. The first run was trying to keep the RPMs up above 2500 and accelerating and decelerating fairly hard to seat the rings. Have boost limited to 5psi for the moment, and the first break in runs will be done this weekend with any luck.

The most important thing before driving it is getting the exhaust properly hung because the hangar broke on the passenger side and it's being held up with mechanics wire. I also plan to flush the injectors and get proper coolant in it before I can really start to take it out for long runs.

Looking forward to hopefully bringing it to the meet Wednesday provided nothing else goes wrong!!

[immorality]

Woot! Congrats on getting her back on the road.

[macatak]

^+1

that's fantastic Sarah. be great to see her on the road again!

[PearlWhiteMR2]

It looks like I won't be making it out to the meet, I am having trouble getting insurance and I need to be able to drive it around on the roads for a while before I take it out of the city away from the shop. I also am not sure how to go about fixing my exhaust hangar just yet, and I'd like to get it back to Toyota so I can put the lip/underbody panels on while it's on a hoist. Plus a couple other little details. It needs a good wash, wax, vacuum, etc.

So if not, I'll have to set up a little drive or something in June for us to all get together and show it off!

[kakucaekz]

Not even a day permit? Damn.

[macatak]

Sarah
which end of the hanger is the problem

[PearlWhiteMR2]

Well the pipes from the muffler are pretty rusty so the hangars on them are rusty too. They all need to be replaced. The hangar itself broke free from the tailpipe on the passenger side. The hangar is still attached to the car's mount.